Fabrication and excellent performance of amorphous FeSiBCCr/organic-inorganic hybrid powder core

Abstract

Soft magnetic composites (SMCs) are widely used in relevant inductance components in power and electronic fields. The development of high frequency devices requires SMCs to exhibit good insulation and excellent soft magnetic properties. The insulation coating for SMCs is crucial, and it is necessary to ensure that the coating thickness is uniform and maintains excellent adhesion to the powder. In the present work, a novel and efficient solution for the formation of insulating coatings, i.e. phytic acid/silane (denoted as PAS) organic-inorganic hybrid solution, was prepared by the condensation reaction between PA and γ-(2,3-epoxypropoxy) propyl trimethoxy silane. The FeSiBCCr@PAS powder with a core-shell structure has been successfully prepared through chemical reaction in a modified PAS solution. The effects of insulating coating content on the magnetic and mechanical properties of FeSiBCCr@PAS powder cores were systematically investigated. The PAS hybrid insulating coating can significantly improve the DC-bias performance and reduce the core loss. The optiomal powder core, which was prepared by using the powder coated with 3 g/L phytic acid, exhibits a minimum core loss (P50mT/1MHz) of 2979.2 mW/cm3, high effective permeability μe(0.1A/m) of 33.8, and superior DC-bias(100Oe) performance of 80.8%. Present work developed an effective method to prepare high performance powder cores with good soft magnetic and mechanical properties.